WO1992013645A1 - Procede et dispositif de fabrication de panneaux de ciment renforces - Google Patents
Procede et dispositif de fabrication de panneaux de ciment renforces Download PDFInfo
- Publication number
- WO1992013645A1 WO1992013645A1 PCT/US1991/009452 US9109452W WO9213645A1 WO 1992013645 A1 WO1992013645 A1 WO 1992013645A1 US 9109452 W US9109452 W US 9109452W WO 9213645 A1 WO9213645 A1 WO 9213645A1
- Authority
- WO
- WIPO (PCT)
- Prior art keywords
- web
- fabric
- slurry
- core layer
- depositing
- Prior art date
Links
- 238000000034 method Methods 0.000 title claims abstract description 25
- 238000004519 manufacturing process Methods 0.000 title description 8
- 239000002002 slurry Substances 0.000 claims abstract description 151
- 239000004744 fabric Substances 0.000 claims abstract description 102
- 230000008093 supporting effect Effects 0.000 claims abstract description 60
- 230000003014 reinforcing effect Effects 0.000 claims abstract description 28
- 239000000463 material Substances 0.000 claims abstract description 27
- 239000012792 core layer Substances 0.000 claims description 70
- 239000000203 mixture Substances 0.000 claims description 18
- 238000000576 coating method Methods 0.000 claims description 15
- 239000011248 coating agent Substances 0.000 claims description 13
- 239000010410 layer Substances 0.000 claims description 12
- 229910001220 stainless steel Inorganic materials 0.000 claims description 8
- 239000002131 composite material Substances 0.000 claims description 3
- 239000003365 glass fiber Substances 0.000 claims description 3
- 229910052751 metal Inorganic materials 0.000 claims description 3
- 239000002184 metal Substances 0.000 claims description 3
- 229920000098 polyolefin Polymers 0.000 claims description 3
- 229910000831 Steel Inorganic materials 0.000 claims description 2
- 239000010959 steel Substances 0.000 claims description 2
- 238000000151 deposition Methods 0.000 claims 43
- 238000007493 shaping process Methods 0.000 claims 5
- 150000001336 alkenes Chemical class 0.000 claims 1
- 238000011437 continuous method Methods 0.000 claims 1
- JRZJOMJEPLMPRA-UHFFFAOYSA-N olefin Natural products CCCCCCCC=C JRZJOMJEPLMPRA-UHFFFAOYSA-N 0.000 claims 1
- -1 for example Substances 0.000 abstract description 10
- 239000011398 Portland cement Substances 0.000 abstract description 9
- 239000004743 Polypropylene Substances 0.000 abstract description 5
- 229920001155 polypropylene Polymers 0.000 abstract description 5
- 238000010276 construction Methods 0.000 abstract description 2
- 239000011162 core material Substances 0.000 description 13
- 229920000642 polymer Polymers 0.000 description 7
- 238000005299 abrasion Methods 0.000 description 6
- 239000011152 fibreglass Substances 0.000 description 6
- 239000010440 gypsum Substances 0.000 description 6
- 229910052602 gypsum Inorganic materials 0.000 description 6
- 239000004568 cement Substances 0.000 description 4
- 238000009432 framing Methods 0.000 description 4
- 229920001778 nylon Polymers 0.000 description 4
- 239000004800 polyvinyl chloride Substances 0.000 description 4
- 229920000915 polyvinyl chloride Polymers 0.000 description 4
- VYZAMTAEIAYCRO-UHFFFAOYSA-N Chromium Chemical compound [Cr] VYZAMTAEIAYCRO-UHFFFAOYSA-N 0.000 description 3
- 239000004677 Nylon Substances 0.000 description 3
- 239000011324 bead Substances 0.000 description 3
- 229910052804 chromium Inorganic materials 0.000 description 3
- 239000011651 chromium Substances 0.000 description 3
- 239000004567 concrete Substances 0.000 description 3
- 239000000835 fiber Substances 0.000 description 3
- 230000008569 process Effects 0.000 description 3
- 239000010935 stainless steel Substances 0.000 description 3
- CPLXHLVBOLITMK-UHFFFAOYSA-N Magnesium oxide Chemical compound [Mg]=O CPLXHLVBOLITMK-UHFFFAOYSA-N 0.000 description 2
- VVQNEPGJFQJSBK-UHFFFAOYSA-N Methyl methacrylate Chemical compound COC(=O)C(C)=C VVQNEPGJFQJSBK-UHFFFAOYSA-N 0.000 description 2
- 239000004698 Polyethylene Substances 0.000 description 2
- 239000004793 Polystyrene Substances 0.000 description 2
- 229920006362 Teflon® Polymers 0.000 description 2
- 230000002378 acidificating effect Effects 0.000 description 2
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- 239000011092 plastic-coated paper Substances 0.000 description 2
- 229920000728 polyester Polymers 0.000 description 2
- 229920000573 polyethylene Polymers 0.000 description 2
- 230000001105 regulatory effect Effects 0.000 description 2
- 239000007921 spray Substances 0.000 description 2
- 229920000785 ultra high molecular weight polyethylene Polymers 0.000 description 2
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 2
- 101100119767 Caenorhabditis elegans fat-4 gene Proteins 0.000 description 1
- 101100468762 Caenorhabditis elegans ric-3 gene Proteins 0.000 description 1
- 229910000975 Carbon steel Inorganic materials 0.000 description 1
- 101100536354 Drosophila melanogaster tant gene Proteins 0.000 description 1
- 239000004593 Epoxy Substances 0.000 description 1
- 208000029154 Narrow face Diseases 0.000 description 1
- 229920000572 Nylon 6/12 Polymers 0.000 description 1
- 229920005372 Plexiglas® Polymers 0.000 description 1
- 239000004721 Polyphenylene oxide Substances 0.000 description 1
- 239000004734 Polyphenylene sulfide Substances 0.000 description 1
- 229920001328 Polyvinylidene chloride Polymers 0.000 description 1
- 239000004809 Teflon Substances 0.000 description 1
- ATJFFYVFTNAWJD-UHFFFAOYSA-N Tin Chemical compound [Sn] ATJFFYVFTNAWJD-UHFFFAOYSA-N 0.000 description 1
- 229910052770 Uranium Inorganic materials 0.000 description 1
- 229920001807 Urea-formaldehyde Polymers 0.000 description 1
- HCHKCACWOHOZIP-UHFFFAOYSA-N Zinc Chemical compound [Zn] HCHKCACWOHOZIP-UHFFFAOYSA-N 0.000 description 1
- 150000001241 acetals Chemical class 0.000 description 1
- 239000003513 alkali Substances 0.000 description 1
- 229910052782 aluminium Inorganic materials 0.000 description 1
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 description 1
- PNEYBMLMFCGWSK-UHFFFAOYSA-N aluminium oxide Inorganic materials [O-2].[O-2].[O-2].[Al+3].[Al+3] PNEYBMLMFCGWSK-UHFFFAOYSA-N 0.000 description 1
- 230000015572 biosynthetic process Effects 0.000 description 1
- 150000001768 cations Chemical class 0.000 description 1
- 239000000919 ceramic Substances 0.000 description 1
- 230000008859 change Effects 0.000 description 1
- 125000003636 chemical group Chemical group 0.000 description 1
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- 238000007334 copolymerization reaction Methods 0.000 description 1
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- CEJLBZWIKQJOAT-UHFFFAOYSA-N dichloroisocyanuric acid Chemical compound ClN1C(=O)NC(=O)N(Cl)C1=O CEJLBZWIKQJOAT-UHFFFAOYSA-N 0.000 description 1
- 230000000694 effects Effects 0.000 description 1
- 229920001971 elastomer Polymers 0.000 description 1
- 125000003700 epoxy group Chemical group 0.000 description 1
- HQQADJVZYDDRJT-UHFFFAOYSA-N ethene;prop-1-ene Chemical group C=C.CC=C HQQADJVZYDDRJT-UHFFFAOYSA-N 0.000 description 1
- 229920002313 fluoropolymer Polymers 0.000 description 1
- 239000011521 glass Substances 0.000 description 1
- 238000005552 hardfacing Methods 0.000 description 1
- XLYOFNOQVPJJNP-UHFFFAOYSA-M hydroxide Chemical compound [OH-] XLYOFNOQVPJJNP-UHFFFAOYSA-M 0.000 description 1
- 238000009434 installation Methods 0.000 description 1
- 239000000395 magnesium oxide Substances 0.000 description 1
- 239000004579 marble Substances 0.000 description 1
- 150000002739 metals Chemical class 0.000 description 1
- MYWUZJCMWCOHBA-VIFPVBQESA-N methamphetamine Chemical compound CN[C@@H](C)CC1=CC=CC=C1 MYWUZJCMWCOHBA-VIFPVBQESA-N 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
- 239000004570 mortar (masonry) Substances 0.000 description 1
- 239000003973 paint Substances 0.000 description 1
- 239000002245 particle Substances 0.000 description 1
- ISWSIDIOOBJBQZ-UHFFFAOYSA-N phenol group Chemical group C1(=CC=CC=C1)O ISWSIDIOOBJBQZ-UHFFFAOYSA-N 0.000 description 1
- 229920001568 phenolic resin Polymers 0.000 description 1
- 229920003023 plastic Polymers 0.000 description 1
- 239000004033 plastic Substances 0.000 description 1
- 229920002492 poly(sulfone) Polymers 0.000 description 1
- 239000004417 polycarbonate Substances 0.000 description 1
- 229920000515 polycarbonate Polymers 0.000 description 1
- 229920000647 polyepoxide Polymers 0.000 description 1
- 238000006116 polymerization reaction Methods 0.000 description 1
- 239000004926 polymethyl methacrylate Substances 0.000 description 1
- 229920006380 polyphenylene oxide Polymers 0.000 description 1
- 229920000069 polyphenylene sulfide Polymers 0.000 description 1
- 229920001296 polysiloxane Polymers 0.000 description 1
- 229920002223 polystyrene Polymers 0.000 description 1
- 239000004810 polytetrafluoroethylene Substances 0.000 description 1
- 229940058401 polytetrafluoroethylene Drugs 0.000 description 1
- 239000005033 polyvinylidene chloride Substances 0.000 description 1
- 239000008262 pumice Substances 0.000 description 1
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- 229920003002 synthetic resin Polymers 0.000 description 1
- 239000000057 synthetic resin Substances 0.000 description 1
- 239000011467 thin brick Substances 0.000 description 1
- 229910052718 tin Inorganic materials 0.000 description 1
- 230000037303 wrinkles Effects 0.000 description 1
- 229910052725 zinc Inorganic materials 0.000 description 1
- 239000011701 zinc Substances 0.000 description 1
Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
- B32B5/02—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer
- B32B5/024—Woven fabric
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B38/00—Ancillary operations in connection with laminating processes
- B32B38/08—Impregnating
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B28—WORKING CEMENT, CLAY, OR STONE
- B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
- B28B19/00—Machines or methods for applying the material to surfaces to form a permanent layer thereon
- B28B19/0015—Machines or methods for applying the material to surfaces to form a permanent layer thereon on multilayered articles
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B28—WORKING CEMENT, CLAY, OR STONE
- B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
- B28B19/00—Machines or methods for applying the material to surfaces to form a permanent layer thereon
- B28B19/0092—Machines or methods for applying the material to surfaces to form a permanent layer thereon to webs, sheets or the like, e.g. of paper, cardboard
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B28—WORKING CEMENT, CLAY, OR STONE
- B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
- B28B23/00—Arrangements specially adapted for the production of shaped articles with elements wholly or partly embedded in the moulding material; Production of reinforced objects
- B28B23/0006—Arrangements specially adapted for the production of shaped articles with elements wholly or partly embedded in the moulding material; Production of reinforced objects the reinforcement consisting of aligned, non-metal reinforcing elements
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B28—WORKING CEMENT, CLAY, OR STONE
- B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
- B28B5/00—Producing shaped articles from the material in moulds or on moulding surfaces, carried or formed by, in or on conveyors irrespective of the manner of shaping
- B28B5/02—Producing shaped articles from the material in moulds or on moulding surfaces, carried or formed by, in or on conveyors irrespective of the manner of shaping on conveyors of the endless-belt or chain type
- B28B5/026—Producing shaped articles from the material in moulds or on moulding surfaces, carried or formed by, in or on conveyors irrespective of the manner of shaping on conveyors of the endless-belt or chain type the shaped articles being of indefinite length
- B28B5/027—Producing shaped articles from the material in moulds or on moulding surfaces, carried or formed by, in or on conveyors irrespective of the manner of shaping on conveyors of the endless-belt or chain type the shaped articles being of indefinite length the moulding surfaces being of the indefinite length type, e.g. belts, and being continuously fed
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B13/00—Layered products comprising a a layer of water-setting substance, e.g. concrete, plaster, asbestos cement, or like builders' material
- B32B13/14—Layered products comprising a a layer of water-setting substance, e.g. concrete, plaster, asbestos cement, or like builders' material next to a fibrous or filamentary layer
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2305/00—Condition, form or state of the layers or laminate
- B32B2305/02—Cellular or porous
- B32B2305/028—Hollow fillers; Syntactic material
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2607/00—Walls, panels
Definitions
- This invention relates to the production of fabric-rein ⁇ forced cementitious panels including gypsum wallboard, light-weight concrete panels, tile backerboards, and the like.
- cementitious panels are; fastene'd to the framing of a wall or building exterior or over a sub-floor, to serve as a backerboard for the installation of a facing material such as ceramic tile, thin brick, thin marble panels and stucco.
- a facing material such as ceramic tile, thin brick, thin marble panels and stucco.
- they also are used with ⁇ out a hard facing material as with the application of a layer of paint or wallpaper.
- this invention relates to a novel meth ⁇ od and apparatus for producing cementitious backerboards comprising a panel having a core of lightweight concrete with the faces being reinforced with a layer of fabric bonded thereto.
- cementitious panels are described in U. S. Patent No. 3,284,980 (1966) P. E. Dinkel, U. S. Patent No. 4,450,022 (1984) R. E. Galer et al and U. S. Patent No- 4,916,004 (1990) , R. P. Ensminger et al.
- These panels are nailable and are readily fastened to framing members and the like with nails, screws or other fasteners. Since the panels are of concrete they are substantially unaffected by water and consequently find extensive use in wet areas such as shower enclosures, bathtub surrounds, kitchen areas and entryways as well as on building exteriors.
- my invention is not limited to the production of cementitious backerboards having a core of lightweight con ⁇ crete.
- panels having a gypsum core such as the gypsum boards with a fibrous mat face as described in U. S. Patent No. 4,810,569 (1989) , B. G. Randall.
- Other examples of gypsum wallboards are des ⁇ cribed in ⁇ . S. Patent No. 4,518,652 (1985), M. D. ill- oughby, and U. S. Patent No. 3,993 r 822 (1973) , A. Knauf.
- Cementitious panels are generally produced employing a core mix of water, a cementitious material (e.g., portland cement, magnesia cement, alumina cement, gypsum and blends thereof) and a lightweight aggregate (e.g., expanded clay r expanded slag, expanded shale, perlibe, pumice, expanded glass beads and polystyrene beads) .
- the core may also contain foamed gypsum or foamed portland cement composi ⁇ tions, and may contain no aggregate.
- the reinforcing fabric most generally employed is a fiber-glass scrim, in particular, a woven mesh of poly- vinylchloride coated glass-fiber yarns.
- the fabric is bonded to the core by a cementitious slurry, for example, a portland cement slurry, or is bonded by the core mix composition itself extending through the-openings in the abric. ' - ' " - ""
- the reinforcing fabric is per ⁇ vious; the openings in the mesh, scrim or other fabric are sufficiently large to permit passage of the fabric bonding material such as a portland cement slurry with or without an aggregate added.
- Fabrics other than glass- fiber meshes such as fabrics of synthetic resin fibers, for example, nylon fibers, polyvinylidene chloride fibers and polyester fiber yarns coated with PVC, can be used.
- Recently fabric reinforced panels with fabric-wrapped edges have been introduced.
- the fabric reinfor ⁇ ces the longitudinal edges to provide better edge strength. Where a nail or screw is inserted close to the edge of a panel in fastening to the narrow face of a stud or other framing member the fabric minimizes break out of edge and provides more secure attachment of the panel to the framing.
- My invention relates to a novel means for applying a cementitious slurry to a moving web of a pervious rein ⁇ forcing fabric and furthermore for applying slurry in a selected longitudinal section. It has particular appli ⁇ cation in the production of the wrapped-edge type fabric reinforced panel.
- the web of fabric is passed over a sup ⁇ porting member such as a plate, a cementitious slurry is fed to the upper surface of the web and then is spread uniformly over the web in controlled amount by means of a doctor (blade, bar or roller) adjustably spaced from the supporting member or by other means as described herein.
- the web is drawn out of the slot formed by the doctor and supporting 1ate, hereby applying the desired coating of slurry; the web is then deposited upon the appropriate surface. If it is the first web it is deposited upon the carrier (e.g., a plastic coated paper web or olastic carrier sheet) on which the panels are formed. If it is the second web it is deposited upon the upper face of the core layer.
- the carrier e.g., a plastic coated paper web or olastic carrier sheet
- the web of fabric as it is drawn over the plate, is suitably coated with a layer of the slurry in the desired amount on the bottom surface as well as on the top surface and openings in the web are filled.
- the slurry there is little or no tendency for the slurry to cling to such a supporting plate and consequently this eliminates the tendency to drag the slurry off the bottom surface of the web.
- the slurry is wiped off of the surface of the web there will be an inadequate amount of material to effect bonding to the core layer. This is especially true in the case of the top or second web which must be laid down on the core layer.
- Cementitious slurries such as a portland slurry
- a portland cement slurry is very alkaline with a pH of at least 11-12, due to the presence of cal ⁇ cium hydroxide.
- These slurries tend to react with, or have an affinity for, base-reactive surfaces and conse ⁇ quently have a decided tendency to cling to these sur- faces.
- With a supporting plate of a base-reactive mater ⁇ ial the slurry in a large measure is wiped off the bottom face of the fabric web.
- base-reactive (or acidic) materials are certain metals such as aluminum, tin and zinc and polymers such as acetals, polyesters, polycarbonates and silicones, and phenolic and urea- formaldehyde resins .
- Non-base-reactive materials which I have found to be suitable as the surface of the supporting plate include various polymers; polyethylene, polypropylene, poly- styrene, fluorocarbon polymers ("Teflons”) such as poly- tetrafluoroethylene and perfluoro (ethylene/propylene. copolymers) , methyl methacrylate polymer ( "Plexiglas”) , various nylon resins such as nylon 612 ⁇ r a"Nylotron GX" sheet., polyphenylene oxide, polyphenylene sulfide and polysulfones. These are by way of example and are not intended to be exclusive of other non-base-reactive poly ⁇ mers..Because of.
- the supporting plate can be entirely non-base-reactive material or only the surface of the plate can be of a non-base-reactive material.
- a polymer which in one form may function properly as a non-base-reactive surface may fail if used in a modified form or may fail due to the operating environment.
- An example is a rigid polyvinylchloride plate which can be ⁇ come base-reactive due to the tendency of PVC to dehalo- genate under certain conditions resulting in an acidic surf,ace. Good smoothness of the surface of the. supporting member is a factor. Normally the surface of the supporting mem ⁇ ber, such as a new polypropylene plate, nylon plate or stainless steel plate will be smooth as installed.
- stainless steels provide not only a non-base- reactive surface but also good abrasion resistance and per it longer running time.
- Stainless steels such as SS 304 and SS 316L work well, providing a surface life substantially in excess of two weeks.
- the chromium used in the stainless steels lends passivity to -provide a strong non-base-reactive surface.
- a chromium plated steel plate also provides a very good non-base-reactive abrasion- resistant surface as the supporting member.
- the surface of the stainless steel or chromium plated member should be ground and/or polished to provide a smooth and true face.
- the supporting member must present a true plane in the transverse direction, at least at the point where the web of mesh passes under the doctor blade, or if no doctor is employed, then at the point at which the mesh leaves the member. Otherwise the coating of slurry deposited upon the mesh will be non-uniform. If the surface is out as little as 0.005" from the true plane the result can be unwanted heavily coated areas, for example, a bead along the edge.
- non-base-reactive material thus de ⁇ pends upon the use to be made and the operating conditions and economics.
- the "Azdel" polypropylene composite sheet can be employed.
- the "Teflon" polymers afford good alkali resistance (non-base-reactive) but are not abrasion resis ⁇ tant.
- the UHMW polyolefins are not only non-base- reactive but also abrasion resistant, a plate uf the mater- ial is difficult to hold in a true plane.
- Certain rubber ⁇ ized coatings or elastomeric coatings which provide a non- base-reactive sarface having desirable abrasion resistance can be used if bonded to a substrate in a true plane.
- the surface of the doctor also should be of a non--base-reactive material, such as a polymeric material,to minimize clinging of the slurry to the doctor, thus reducing any tendency of the doctor to wipe bare the top surface of the web. It is necessary that the working edge of the doctor and the face of the supporting member be matched to provide a uniform slot.
- My invention includes means for producing fabric reinforced cementitious panels having fabric-wrapped lon ⁇ gitudinal edges and in particular it includes means for producing such panels with the fabric on the edges being substantially open and free of slurry or the like.
- Such panels, having open fabric along the longitudinal edges, offer the advantage of improved edge-to-edge bonding of the panels when they are installed abutting each other as in the construction of a wall.
- the first web of reinforcing fabric (which forms the bottom layer of the panel) is wider than the panel width; the center section of the web receives the core layer and a margin section of the web on each side of the center is folded over to wrap each of the two edges of the core layer and also to extend over on to the top face of the core layer.
- the slurry is applied only in the longitudinally extending center section of this web where it is to be bonded to the bottom face of the core layer.
- a second web of fabric with slurry applied is deposited upon the top surface of the core layer to cover the top surface and to overlay the margin strips of the bottom web that have been folded over the edges. Bonding material such as a portland cement slurry is ap ⁇ plied to the second web either before or after it is laid down on the core layer.
- Fig. 1 is a diagram of the sequence of steps e - ployed in producing fabric-rein orced cementitious panels.
- Figs. 2A-2D illustrate, in cross-sectional views, the steps of placing the fabric web, in the formation of wrapped-edge cementitious panels having open-mesh edges.
- Fig. 3 is a partial cross-sectional view of a fabric-reinforced cementitious panel with an open-mesh wrapped edge.
- Fig. 4 is a side view of the slurry applicator.
- Fig. 5 is a side view of a modified slurry appli ⁇ cator with guides.
- Fig. 6 is a top view of a web of reinforcing fabric at the slurry application station showing application of the slurry to a selected longitudinal section of the web
- Fig. 7 is a side view of a second embodiment of my slurry applicator which requires no doctor.
- Fig. 8 is a side view of my slurry applicator which employs an air knife doctor.
- Fig. 1 illustrates, diagra atically, a conventional process for producing fabric-reinforced cementitious panels.
- the panels are formed on abutting carrier sheets on a moving conveyor belt.
- Methods and apparatus for forming such panels on a web of plastic coated paper deposited on a conveyor belt are dis ⁇ closed in U.S.Patent No. 4,298,413 (1981) Teare, and in U.S.Patent No. 4,450,022 (1984) , Galer.
- Figs. 2A-2D illustrate in cross-sectional views the sequence of steps in the folding of the fabric web to form a wrapped-edge, fabric-reinforced cementitious panel with the section of fabric on each of the longit ⁇ udinal edges of the panel being open and unbonded.
- Numeral 2 indicates one of several abutting plastic carrier sheets supported on a moving conveyor belt 1.
- a web of woven fiber-glass mesh 4 (first mesh) coated in center section 9 with a portland cement slurry 5, is deposited on carrier sheet 2; the two margin sec ⁇ tions 10 and 10' of the mesh are left unslurried.
- Numer- al 4a indicates the slurried web.
- Fig. 2B the two margin sections 10 and 10" are folded upward by suitable guides into a more or less ver ⁇ tical position after the core mix is deposited upon the slurried center section 9 and shaped to form the core layer 12.
- the bottom of core layer 12 becomes bonded to the center section 9 of mesh 4 by slurry 5.
- Fig. 2C the margin sections 10 and 10 ' of mesh 4 are folded over onto the top face 11 of core layer 12.
- a second web of woven fiber-glass mesh 14 (second mesh) coated with a portland cement slurry 13 is laid on top face 11 of core layer 12, covering the portions of the margin sections 10 and 10 ' of mesh 4 which are folded over on the top face of the core layer.
- the top web 14 can be coated with slurry before or after it is l id down upon the core. The edges of the mesh 4 thus become bonded to the top face of the core layer 12 at 15 and 15 ' and to the web of mesh 14 by virtue of the slurry 13 applied to the mesh 14.
- a fabric-reinforced cementi ⁇ tious panel web (as a wet ribbon) suitable for cutting into individual panels is thus formed.
- Fig. 3 shows a partial cross-sectional view of a rapped-edge fiber-reinforced cementitious panel as form ⁇ ed by the foregoing steps. Specifically, it shows the mesh on the wrapped edge of the panel as being open, num ⁇ eral 16, that is, substantially free of slurry and core material, in a condition to receive the edge bonding material (mortar, etc.)
- edge bonding material memory, etc.
- a novel slurry applicator This is des- 5 cribed with reference to Fig. 4. It is described in this part of the specification as the applicator for the first mesh as discussed under Fig. 2A.
- the slurried web 4a is then laid down on carrier sheets 2 moving on. conveyor belt 1. 5
- the doctor 6 is adjustably spaced from the supporting plate 3 to permit control of the amount of slurry applied to the web 4. End dams 8, separately mounted but co- acting with doctor 6, confine the slurry.
- the ⁇ surface of the supporting plate must be a non-base-reac ⁇ tive material, for example, nylon, UHMW polyethylene or stainless steel.
- the entire plate is of a non- base-reactive material although it is sufficient that the surface of the plate is a non-base-reactive material .
- j - I have found that by using such a non-base-reactive sup ⁇ porting plate, the web can be fully coated on both sur ⁇ faces with sufficient layer of slurry, on the bottom face, as well as the top face, in one simple operation.
- Fig. 6 the application of slurry to a selected longitudinal section of the web (in this example, the central section) is shown.
- a web of reinforcing fabric 4 is advanced over supporting plate 3 which is of a suit ⁇ able length to span the width of the web 4.
- Doctor blade 6 is suitably mounted above plate 3 and adjustably spaced therefrom.
- Adjustable end-da s 8' arid 8 independently mounted but in co-acting relationship with doctor 6, are spaced to the desired width 9 of application of slurry 5,
- the slurry 5 is fed to the doctor area by means of hose 5a.
- the selected section 9 of the web will be properly coated with slurry 5, top and bottom faces and the openings in the mesh filled, while the margin sections 10 and 10' will be free of slurry, (i.e. for the open- mesh edges) .
- a doctor to spread the slurry uniformly over the mesh is eliminated.
- This slurry coater is shown in Fig. 7.
- the supporting member, plate 3 is inclined upward in the direction of travel of the mesh web 4.
- Slurry 5 is spray ⁇ ed across the desired width of the web by spray nozzles 5b, in controlled amount to provide the desired coating of slurry on the mesh.
- Adjustable side dams (not shown) define the width of the longitudinal area of the mesh web being coated.
- the length of plate 3 and its angle of in ⁇ clination are regulated to permit the slurry to level out before the mesh 4a leaves plate 3.
- the non-base- reactive nature of the surface of plate 3 makes this method feasible.
- an air knife shown at 17, is employed to spread the slurry uniformly over the mesh and to roll back the excess slurry.
- slurry 5 is fed from pipe 5a.
- Pressurized air is fed to the air knife 17 from air line 18.
- a thin blade of air emitted from nozzle 19 removes the excess slurry 5c leaving a uniform coating of slurry on the mesh
- Adjustable side dams not shown, control the width of the longitudinal area of the mesh that is being coated. Excess slurry 5c flows off the end of plate 3 and is caught in pan 20 for recycling.
- the amount of slurry retained on mesh at 4a is regulated by the air pressure and angle of incidence of the air knife.
- My slurry applicator Fig. 4 or Fig. 5, is adapted to apply slurry to the full width of a web of fabric, as well as to selected longitudinal sections, by use of a sufficiently long doctor and by suitable placement of the end-dams.
- the web of mesh 14 in Fig. 2D for example, can be coated with slurry across its full width.
- my invention is also useful in producing wrap ⁇ ped-edge fabric reinforced panels of the type having ce- mentitious bonding material covering and embedding the reinforcing fabric on all of the surfaces, that is on the top and bottom faces of the core as well as along the longitudinal edges.
- Such panels are described in U.S. Patent No. 4,916,004 (Ensminger) .
- the end-dams of my slurry applicator are set to the full width of the web
- a roll having a non-base-reactive surface offers the advantage that at such time as a given axial Q area of its surface becomes worn the roll can be rota ⁇ ted a few degrees to present a non-worn surface area. This would reduce or eliminate the time required to re ⁇ place the supporting member.
Landscapes
- Engineering & Computer Science (AREA)
- Chemical & Material Sciences (AREA)
- Ceramic Engineering (AREA)
- Mechanical Engineering (AREA)
- Manufacturing & Machinery (AREA)
- Textile Engineering (AREA)
- Structural Engineering (AREA)
- Laminated Bodies (AREA)
- Producing Shaped Articles From Materials (AREA)
- Manufacturing Of Tubular Articles Or Embedded Moulded Articles (AREA)
Abstract
L'invention décrit un procédé et un dispositif servant à fabriquer des panneaux de construction légers, dont l'intérieur en ciment est recouvert par une couche formée par une toile de renforcement, adhérant aux deux faces de l'intérieur dudit panneau. Les bords du panneau sont également recouverts par la toile. On applique le ciment liquide, par exemple du ciment Portland, à la toile au moyen d'une plaque de support au-dessus de laquelle on tire la toile et on monte une raclette en position réglable sur la plaque. La plaque de support est constituée par un matériau ne réagissant pas aux bases, tel que du polypropylène; l'utilisation de ladite plaque permet une meilleure application du ciment liquide à la toile.
Applications Claiming Priority (4)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US64946891A | 1991-02-01 | 1991-02-01 | |
US649,468 | 1991-02-01 | ||
US72898491A | 1991-07-12 | 1991-07-12 | |
US728,984 | 1991-07-12 |
Publications (1)
Publication Number | Publication Date |
---|---|
WO1992013645A1 true WO1992013645A1 (fr) | 1992-08-20 |
Family
ID=27095610
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
PCT/US1991/009452 WO1992013645A1 (fr) | 1991-02-01 | 1991-12-16 | Procede et dispositif de fabrication de panneaux de ciment renforces |
Country Status (6)
Country | Link |
---|---|
JP (1) | JPH06198618A (fr) |
KR (1) | KR920016203A (fr) |
AU (1) | AU1255792A (fr) |
CA (1) | CA2060060A1 (fr) |
MX (1) | MX9200213A (fr) |
WO (1) | WO1992013645A1 (fr) |
Cited By (5)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
WO2009111292A3 (fr) * | 2008-03-03 | 2009-10-29 | United States Gypsum Company | Panneaux blindés stratifiés à base de ciment |
WO2009111302A3 (fr) * | 2008-03-03 | 2009-10-29 | United States Gypsum Company | Système de panneau blindé à base de ciment |
US8030377B2 (en) | 2008-03-03 | 2011-10-04 | United States Gypsum Company | Self-leveling cementitious composition with controlled rate of strength development and ultra-high compressive strength upon hardening and articles made from same |
US8061257B2 (en) | 2008-03-03 | 2011-11-22 | United States Gypsum Company | Cement based armor panel system |
US8137490B2 (en) | 2008-03-03 | 2012-03-20 | United States Gypsum Company | Process of manufacturing cement based armor panels |
Families Citing this family (3)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US6508895B2 (en) | 1998-09-09 | 2003-01-21 | United States Gypsum Co | Method of producing gypsum/fiber board |
US7897079B2 (en) * | 2006-09-21 | 2011-03-01 | United States Gypsum Company | Method and apparatus for scrim embedment into wet processed panels |
IT201900005300A1 (it) * | 2019-04-05 | 2020-10-05 | Milano Politecnico | Elemento di rivestimento per l’impiego in edilizia e metodo per la sua realizzazione |
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1991
- 1991-12-16 AU AU12557/92A patent/AU1255792A/en not_active Abandoned
- 1991-12-16 WO PCT/US1991/009452 patent/WO1992013645A1/fr active Application Filing
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1992
- 1992-01-17 MX MX9200213A patent/MX9200213A/es unknown
- 1992-01-23 KR KR1019920000916A patent/KR920016203A/ko not_active Application Discontinuation
- 1992-01-27 CA CA002060060A patent/CA2060060A1/fr not_active Abandoned
- 1992-01-31 JP JP4040443A patent/JPH06198618A/ja active Pending
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Cited By (10)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
WO2009111292A3 (fr) * | 2008-03-03 | 2009-10-29 | United States Gypsum Company | Panneaux blindés stratifiés à base de ciment |
WO2009111302A3 (fr) * | 2008-03-03 | 2009-10-29 | United States Gypsum Company | Système de panneau blindé à base de ciment |
CN101970975A (zh) * | 2008-03-03 | 2011-02-09 | 美国石膏公司 | 基于水泥的叠层铠装面板 |
CN101970976A (zh) * | 2008-03-03 | 2011-02-09 | 美国石膏公司 | 基于水泥的铠装面板系统 |
US8030377B2 (en) | 2008-03-03 | 2011-10-04 | United States Gypsum Company | Self-leveling cementitious composition with controlled rate of strength development and ultra-high compressive strength upon hardening and articles made from same |
US8061257B2 (en) | 2008-03-03 | 2011-11-22 | United States Gypsum Company | Cement based armor panel system |
US8062741B2 (en) | 2008-03-03 | 2011-11-22 | U.S. Gypsum Company | Cement based laminated armor panels |
US8137490B2 (en) | 2008-03-03 | 2012-03-20 | United States Gypsum Company | Process of manufacturing cement based armor panels |
RU2487219C2 (ru) * | 2008-03-03 | 2013-07-10 | Юнайтед Стэйтс Джипсум Компани | Слоистые бронепанели на основе цемента |
CN101970976B (zh) * | 2008-03-03 | 2013-08-28 | 美国石膏公司 | 基于水泥的铠装面板系统 |
Also Published As
Publication number | Publication date |
---|---|
AU1255792A (en) | 1992-09-07 |
CA2060060A1 (fr) | 1992-08-02 |
JPH06198618A (ja) | 1994-07-19 |
KR920016203A (ko) | 1992-09-24 |
MX9200213A (es) | 1992-08-01 |
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